U.S. patent application number 14/254163 was filed with the patent office on 2015-10-22 for systems and methods for coalescing internal combustion engine blow-by.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. The applicant listed for this patent is GENERAL ELECTRIC COMPANY. Invention is credited to Paul John Fontecchio, Musarth Ali Khan, Ramprasad Maruti Shetti, Paul Wadding.
Application Number | 20150300222 14/254163 |
Document ID | / |
Family ID | 54321609 |
Filed Date | 2015-10-22 |
United States Patent
Application |
20150300222 |
Kind Code |
A1 |
Khan; Musarth Ali ; et
al. |
October 22, 2015 |
SYSTEMS AND METHODS FOR COALESCING INTERNAL COMBUSTION ENGINE
BLOW-BY
Abstract
A system includes at least one coalescer, a blow-by input
module, and a boost air module. The at least one coalescer is
configured to receive a blow-by mixture, to remove oil from the
blow-by mixture to provide an oil drain supply, and to remove gas
from the blow-by mixture to provide a gas vent supply. The
coalescer is configured to receive an operational air supply. The
blow-by input module is operably coupled to the at least one
coalescer and configured to receive the blow-by mixture from a
crankcase of an internal combustion engine and provide the blow-by
mixture to the at least one coalescer. The boost air module is
operably coupled to the at least one coalescer and configured to
receive an air supply from an intake conduit of the internal
combustion engine and to provide the air supply as the operational
air supply to the at least one coalescer.
Inventors: |
Khan; Musarth Ali;
(Bangalore, IN) ; Shetti; Ramprasad Maruti;
(Bangalore, IN) ; Fontecchio; Paul John; (Erie,
PA) ; Wadding; Paul; (Erie, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ELECTRIC COMPANY |
Schenectady |
NY |
US |
|
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
54321609 |
Appl. No.: |
14/254163 |
Filed: |
April 16, 2014 |
Current U.S.
Class: |
95/272 ; 123/572;
55/385.2 |
Current CPC
Class: |
F01M 13/028 20130101;
F01M 13/021 20130101; F01M 13/04 20130101; F01M 2013/0066
20130101 |
International
Class: |
F01M 13/04 20060101
F01M013/04 |
Claims
1. A coalescing system comprising: at least one coalescer
configured to receive a blow-by mixture from an internal combustion
engine, to remove oil from the blow-by mixture to provide an oil
drain supply from the at least one coalescer, and to remove gas
from the blow-by mixture to provide a gas vent supply from the at
least one coalescer, the at least one coalescer configured to
receive an operational air supply; a blow-by input module operably
coupled to the at least one coalescer and configured to receive the
blow-by mixture from a crankcase of the internal combustion engine
and provide the blow-by mixture to the at least one coalescer; and
a boost air module operably coupled to the at least one coalescer
and configured to receive an air supply from an intake conduit of
the internal combustion engine and to provide the air supply as the
operational air supply to the at least one coalescer.
2. The coalescing system of claim 1, further comprising an outlet
gas module operably coupled to the at least one coalescer and
configured to receive the gas vent supply from the at least one
coalescer and to provide the gas vent supply to an exhaust conduit
of the internal combustion engine.
3. The coalescing system of claim 1, further comprising an oil
output module operably coupled to the at least one coalescer and
configured to receive the oil drain supply from the at least one
coalescer and to provide the oil drain supply to an oil reservoir
of the internal combustion engine.
4. The coalescing system of claim 1, further comprising a bracket
configured to mount the at least one coalescer to a front end of
the internal combustion engine, the front end corresponding to an
intake end of the internal combustion engine.
5. The coalescing system of claim 4, wherein the bracket is
configured to mount the at least one coalescer to an intercooler
disposed on the front end of the internal combustion engine.
6. The coalescing system of claim 5, wherein the bracket comprises
a bracket base and at least one bracket arm, the bracket base
configured to mount to the intercooler, the at least one bracket
arm defining at least one cavity configured to accept at least a
portion of the at least one coalescer, the at least one bracket arm
securable to the bracket base to secure the at least one coalescer
to the intercooler.
7. The coalescing system of claim 6, wherein the at least one
coalescer includes a plurality of coalescers, and the at least one
bracket arm comprises a plurality of bracket arms configured to
secure the plurality of coalescers to the intercooler.
8. The coalescing system of claim 1, wherein the blow-by input
module comprises at least one rigid pipe and at least one flexible
hose.
9. A system comprising: an internal combustion engine comprising an
intake conduit configured to provide an inlet stream of air for
combustion by the internal combustion engine, a crankcase, an
exhaust conduit configured to provide an outlet for combustion
products, and an oil reservoir; at least one coalescer configured
to receive a blow-by mixture from the crankcase of the internal
combustion engine, to remove oil from the blow-by mixture to
provide an oil drain supply from the at least one coalescer, and to
remove gas from the blow-by mixture to provide a gas vent supply
from the at least one coalescer, the at least one coalescer
configured to receive an operational air supply; a blow-by input
module operably coupled to the at least one coalescer and
configured to receive the blow-by mixture from the crankcase of the
internal combustion engine and provide the blow-by mixture to the
at least one coalescer; and a boost air module operably coupled to
the at least one coalescer and configured to receive an air supply
from the intake conduit of the internal combustion engine and to
provide the air supply as the operational air supply to the at
least one coalescer.
10. The system of claim 9, further comprising an outlet gas module
operably coupled to the at least one coalescer and configured to
receive the gas vent supply from the at least one coalescer and to
provide the gas vent supply to the exhaust conduit of the internal
combustion engine.
11. The system of claim 9, further comprising an oil output module
operably coupled to the at least one coalescer and configured to
receive the oil drain supply from the at least one coalescer and to
provide the oil drain supply to the oil reservoir of the internal
combustion engine.
12. The system of claim 9, further comprising a bracket mounted
proximate to a front end of the internal combustion engine, wherein
the intake conduit of the internal combustion engine is disposed
proximate the front end of the internal combustion engine, the at
least one coalescer mounted to the bracket to secure the at least
one coalescer to the front end of the internal combustion
engine.
13. The system of claim 12, wherein the bracket is mounted to an
intercooler disposed on the front end of the internal combustion
engine.
14. A method comprising: positioning at least one coalescer
proximate to an internal combustion engine, the at least one
coalescer configured to receive a blow-by mixture from the internal
combustion engine, to remove oil from the blow-by mixture to
provide an oil drain supply from the at least one coalescer, and to
remove gas from the blow-by mixture to provide a gas vent supply
from the at least one coalescer, the at least one coalescer
configured to receive an operational air supply; operably
connecting a blow-by input module to the at least one coalescer and
to a crankcase of the internal combustion engine, wherein the
blow-by input module receives the blow-by mixture from a crankcase
of the internal combustion engine and provides the blow-by mixture
to the at least one coalescer; and operably connecting a boost air
module to the at least one coalescer and an intake conduit of the
internal combustion engine, wherein the boost air module receives
an air supply from an intake conduit of the internal combustion
engine and provides the air supply as the operational air supply to
the at least one coalescer.
15. The method of claim 14, further comprising operably coupling an
outlet gas module to the at least one coalescer and an exhaust
conduit of the internal combustion engine, wherein the outlet gas
module receives the gas vent supply from the at least one coalescer
and provides the gas vent supply to the exhaust conduit of the
internal combustion engine.
16. The method of claim 14, further comprising operably coupling an
oil output module to the at least one coalescer and to an oil
reservoir of the internal combustion engine, wherein the oil output
module receives the oil drain supply from the at least one
coalescer and provides the oil drain supply to the oil reservoir of
the internal combustion engine.
17. The method of claim 14, further comprising securing the at
least one coalescer to a front end of the internal combustion
engine, the front end corresponding to an intake end of the
internal combustion engine.
18. The method of claim 17, wherein securing the at least one
coalescer to the front end of the internal combustion engine
comprises securing the at least one coalescer to an intercooler
disposed proximate the front end of the internal combustion
engine.
19. The method of claim 18, wherein securing the at least one
coalescer to the intercooler comprises: securing a bracket base to
the intercooler; and securing one or more bracket arms to the
bracket base, the one or more bracket arms comprising at least one
cavity configured to accept at least one of the at least one
coalescers.
20. The method of claim 14, wherein the at least one coalescer
comprises three coalescers mounted to an intercooler disposed
proximate a front end of the internal combustion engine, the front
end corresponding to an intake end of the internal combustion
engine.
Description
BACKGROUND
[0001] During operation of an internal combustion engine, oil may
be mixed with blow-by gases (e.g., gases that have escaped from one
or more cylinders to the crankcase) to create a blow-by mixture in
the crankcase. For efficiency concerns, as well as emission
concerns, it may desirable to remove blow-by from the crankcase and
to use a coalescer to separate the blow-by mixture into gaseous and
oil components.
[0002] Past attempts to utilize coalescers to separate oil from
gases of a blow-by mixture included the mounting of one or more
coalescers at the rear end of an engine (e.g., toward an
alternator) to vent separated gases to a downstream portion of an
after treatment system (ATS). A coalescer boost air supply was
provided from an exhaust system in certain previous attempts to use
coalescers.
[0003] However, certain engine system may not include an ATS for
venting of the separated gases. Further, the routing of hoses and
piping for conventional coalescer systems, for example, on
locomotives may be quite lengthy and/or complex, resulting in
increased difficulty for installation and/or maintenance. Further
still, the coalescers of conventional system may have locations
resulting in difficult installation, difficult access, and/or
inconvenient maintenance. Yet further still, conventional
approaches may result in relatively poor emission levels,
relatively expensive cost, relatively poor reliability, and/or
relatively increased consumption of oil.
BRIEF DESCRIPTION
[0004] In an embodiment, a coalescing system includes at least one
coalescer, a blow-by input module, and a boost air module. The at
least one coalescer is configured to receive a blow-by mixture from
an internal combustion engine, to remove oil from the blow-by
mixture to provide an oil drain supply from the at least one
coalescer, and to remove gas from the blow-by mixture to provide a
gas vent supply from the at least one coalescer. The coalescer is
configured to receive an operational air supply. The blow-by input
module is operably coupled to the at least one coalescer and
configured to receive the blow-by mixture from a crankcase of the
internal combustion engine and provide the blow-by mixture to the
at least one coalescer. The boost air module is operably coupled to
the at least one coalescer and configured to receive an air supply
from an intake conduit of the internal combustion engine and to
provide the air supply as the operational air supply to the at
least one coalescer.
[0005] In another embodiment, a system includes an internal
combustion engine, at least one coalescer, a blow-by input module,
and a boost air module. The internal combustion engine includes an
intake conduit configured to provide an inlet stream of air for
combustion by the internal combustion engine, a crankcase, an
exhaust conduit configured to provide an outlet for combustion
products, and an oil reservoir. The at least one coalescer is
configured to receive a blow-by mixture from the crankcase of the
internal combustion engine, to remove oil from the blow-by mixture
to provide an oil drain supply from the at least one coalescer, and
to remove gas from the blow-by mixture to provide a gas vent supply
from the at least one coalescer. The coalescer is also configured
to receive an operational air supply. The blow-by input module is
operably coupled to the at least one coalescer and configured to
receive the blow-by mixture from the crankcase of the internal
combustion engine and provide the blow-by mixture to the at least
one coalescer. The boost air module is operably coupled to the at
least one coalescer and configured to receive an air supply from
the intake conduit of the internal combustion engine and to provide
the air supply as the operational air supply to the at least one
coalescer.
[0006] In another embodiment, a method includes positioning at
least one coalescer proximate to an internal combustion engine. The
at least one coalescer is configured to receive a blow-by mixture
from an internal combustion engine, to remove oil from the blow-by
mixture to provide an oil drain supply from the at least one
coalescer, and to remove gas from the blow-by mixture to provide a
gas vent supply from the at least one coalescer. The coalescer is
configured to receive an operational air supply. The method also
includes operably connecting a blow-by input module to the at least
one coalescer and to a crankcase of the internal combustion engine,
wherein the blow-by input module receives the blow-by mixture from
a crankcase of the internal combustion engine and provides the
blow-by mixture to the at least one coalescer. Further, the method
includes operably connecting a boost air module to the at least one
coalescer and an intake conduit of the internal combustion engine,
wherein the boost air module receives an air supply from an intake
conduit of the internal combustion engine and provides the air
supply as the operational air supply to the at least one
coalescer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The inventive subject matter will be better understood from
reading the following description of non-limiting embodiments, with
reference to the attached drawings, wherein below:
[0008] FIG. 1 is a schematic block diagram of an engine system,
according to an embodiment of the invention;
[0009] FIG. 2 is a perspective view of the engine system of FIG.
1;
[0010] FIG. 3 is a perspective view of a coalescer system,
according to an embodiment;
[0011] FIG. 4 provides a view of a conduit module, according to an
embodiment;
[0012] FIG. 5 provides a perspective view of a blow-by input
module, according to an embodiment;
[0013] FIG. 6 provides a perspective view of a boost air module,
according to an embodiment;
[0014] FIG. 7 provides a perspective view of an oil supply module,
according to an embodiment;
[0015] FIG. 8 provides a perspective view of an outlet gas module,
according to an embodiment;
[0016] FIG. 9 provides an additional perspective view of the outlet
gas module of FIG. 8;
[0017] FIG. 10 provides a perspective view of a bracket base,
according to an embodiment;
[0018] FIG. 11 provides a perspective view of a bracket with one
coalescer secured by the bracket, according to an embodiment;
[0019] FIG. 12 provides a perspective view of the bracket of FIG.
11 with three coalescers secured by the bracket;
[0020] FIG. 13 provides a perspective view of an alternate mounting
of a coalescer system, according to an embodiment;
[0021] FIG. 14 provides a perspective view of an additional
alternate mounting of a coalescer system, according to an
embodiment; and
[0022] FIG. 15 is a flowchart of a method for providing and using a
coalescer system, according to an embodiment.
DETAILED DESCRIPTION
[0023] One or more examples of the inventive subject matter
described herein provide methods and systems for improved
separation of oil from gases in a blow-by mixture. For example, one
or more coalescers may receive a boost air supply from an intake
conduit of a diesel engine and/or be mounted to a front end (e.g.,
mounted to an EGR intercooler disposed on the front end of the
diesel engine). It may be noted that while the examples discussed
herein are discussed in the context of diesel engines, various
examples may be used with other types of internal combustion
engines. For example, with the one or more coalescers disposed in a
readily accessible location along the front end of an engine and
supplied with a boost air supply from an intake conduit of the
diesel engine, relatively short and/or simple fluid connections
between the one or more coalescers and aspects of the diesel engine
may be utilized.
[0024] At least one technical effect of various examples discussed
herein includes improved engine and/or coalescer efficiency due to
reduced hose and/or piping lengths and/or reducing the oil aerosol
carry over to coalescer units. At least one technical effect of
various examples discussed herein includes improved exhaust
emissions and reduced oil carry over to an exhaust stack (and in
turn to the environment), for example due to improved coalescer
performance resulting from improved routing of one or more of a
boost air supply, a blow-back mixture from a crankcase, a vent gas
supply to an exhaust stack, or an oil return line to an oil
reservoir. At least one technical effect of various examples
discussed herein includes reduced engine lube oil consumption, for
example due to reduced oil carry over to the coalescer. At least
one technical effect of various examples discussed herein includes
reduced cost, for example reduced cost due to improved maintenance
and/or use of fewer coalescers due to improved coalescer
efficiency. At least one technical effect of various examples
discussed herein includes improved accessibility of the system, for
example via use of a readily accessible exterior surface of an EGR
intercooler. At least one technical effect of various examples
discussed herein includes utilization of previously unused or
under-utilized space between a Rad cab and an engine cab. At least
one technical effect of various examples discussed herein includes
flexible and reliable conduit runs, e.g., via the use of a
combination of flexible hoses and rigid piping. At least one
technical effect of various examples discussed herein includes
reduced size and/or weight of mounting brackets and/or hardware for
securing one or more coalescers to a diesel engine.
[0025] FIG. 1 is block diagram and FIG. 2 is perspective view of an
engine system 100 formed in accordance with an embodiment of the
invention. For example, the engine system 100 may be configured as
a diesel engine system for providing motive power for rail
applications or marine applications, among others. As one example,
the engine system 100 may be mounted to a powered rail vehicle
(e.g., locomotive). The depicted engine system 100 includes a
coalescer system 111 and a diesel engine 102.
[0026] The diesel engine 102 is configured as an internal
combustion engine that uses combustion of diesel fuel from a fuel
tank (not shown) and air from an environment to actuate one or more
cylinders that in turn actuate a crank. An output from the crank
may be provided to a generator and used to generate electrical
energy for providing motive power to a vehicle and/or for storage
for later use and/or to power electrical systems of the vehicle.
With continued reference to FIGS. 1 and 2, the diesel engine 102
includes a crank case 103, an integrated front end (IFE) 104, an
oil reservoir 105, an intercooler 106 (e.g., an exhaust gas
recirculation (EGR) unit), a turbo unit 107, an intake conduit 108,
and an exhaust conduit 109. The crank case 103 is configured to
house the crank and to provide lubrication to the crank. The oil
reservoir 105 is configured to store oil for distribution to and
use by various portions of the diesel engine 102 for lubricating
moving parts of the diesel engine 102. The oil reservoir 105 may
include one or more oil pans. The turbo unit 107 may be configured,
for example, to increase the flow and/or pressure of air supplied
to pistons for internal combustion. The intake conduit 108 is
configured to provide air from an environment to the pistons for
combustion. The intake conduit 108 may include one or more intake
ports, tubes, pipes, or hoses for providing air to the cylinders.
The intake conduit 108, for example, may include a manifold
configured to distribute air among cylinders. Further, the intake
conduit 108 may include one or more air filters for removing
particulate from the air before the air is provided to the
cylinders for combustion. The exhaust conduit 109 is configured to
provide a conduit through which exhaust gases (e.g., products of
combustion) from the cylinders may be expelled from the engine
system 100. The exhaust conduit 109 may include, for example, a
muffler and/or rain trap. The intercooler 106 may be configured,
for example as an EGR cooler.
[0027] As best seen in FIG. 2, the engine system 100 includes a
front end 198 and a back end 199. The front end 198, as used
herein, corresponds to an intake end of the engine system 100. The
front end 198 may be understood as one end of the engine as defined
by a long axis of the engine. Further, in various embodiments, the
front end 198 may be disposed opposite an output end that provides
an output to a transmission. As seen in FIG. 2, the intake conduit
108 of the diesel engine 102 is positioned proximate the front end
198. It may be noted that, as seen in the additional view provided
on the right side of FIG. 2, the front end 198 of the diesel engine
102 may not be positioned proximate to or oriented toward a front
end or cab forward position 196 of a powered rail vehicle 197
(e.g., locomotive) to which the diesel engine 102 is mounted. For
example, as seen in FIG. 2, in the illustrated embodiment, the
front end 198 of the diesel engine 102 is oriented toward the back
of the powered rail vehicle 197, or away from the cab forward
position 196 of the powered rail vehicle 197.
[0028] The coalescer system 111 is configured to separate oil from
other portions of a blow-by mixture from the crankcase 103 of the
diesel engine 102. In operation, the compressed fuel/air mixture in
the cylinders of the diesel engine 102 may leak past one or more
pistons to the crankcase. This compressed fuel/air mixture is
referred to herein as blow-by. The blow-by may reduce engine power
and build up pressure in the crankcase to undesirable levels.
However, while in the crankcase, the blow-by may mix with oil
(e.g., an oil mist) in the crankcase, making removal of the blow-by
(e.g., as part of the blow-by mixture) difficult, as well as
expending oil and/or creating undesirable emissions if the blow-by
mixture is released directly to the environment.
[0029] Accordingly, the coalescer system 111 may be used to
separate the oil portion of the blow-by mixture from the gas
portion of the blow-by mixture. It should be noted that as used
herein, the gas portion of the blow-by mixture refers to a gaseous
form of one or more of fuel, air, and/or fuel/air mixture, and not
necessarily to "gasoline." The coalescer system 111 may also be
configured to provide filtration as well.
[0030] The depicted coalescer system 111 includes a coalescer 110,
a blow-by input module 120, a boost air intake module 130, an oil
output module 140, an outlet gas module 150, and a bracket 160. The
coalescer 110 is configured to separate oil from other components
of a blow-by mixture (e.g., a blow-by mixture received from the
crankcase 103 of the diesel engine 102). The blow-by input module
120 is configured to receive a blow-by mixture from the crankcase
103 and provide the blow-by mixture to the coalescer 110. The boost
air intake module 130 is configured to receive an air supply from
the intake conduit 108 of the diesel engine 102, and to provide the
air supply as an operational air supply to the coalescer 110. The
oil output module 140 is configured to receive an oil drain supply
provided by the coalescer 110 (e.g., a supply of oil separated from
the blow-by mixture by the coalescer 110), and to provide the oil
drain supply to the oil reservoir 105. The outlet gas module 150 is
configured to receive a gas vent supply from the coalescer 110
(e.g., a gas vent supply including a gas from a blow-by mixture
from which oil has been separated or removed, and/or including air
from the operational air supply provided from the intake conduit
108 via the boost air module 130), and to provide the gas vent
supply to the exhaust conduit 109. The bracket 160 is configured to
secure the coalescer 110 to the diesel engine 102. In the
illustrated embodiment, the coalescer 110 is secured to the diesel
engine 102 proximate the front end 198 of the diesel engine 102,
for example to an intercooler 106, via the bracket 160.
[0031] As seen in FIG. 1, various blocks are interconnected or
otherwise associated with one or more other blocks via solid lines
terminating in an arrow and/or dotted lines. As shown in FIG. 1, a
solid line terminating in an arrow indicates the flow of a fluid
(e.g., a gas or a liquid, or a mixture thereof), with the arrow
indicating the direction of the flow. A dotted line indicates a
mechanical interface or connection. A dotted line between blocks of
FIG. 1 may represent one or more of bolted or otherwise secured
joints, clamps, threaded fittings, gaskets, or seals between the
blocks configured for mating, joining, securing, or otherwise
associating the two blocks mechanically or physically.
[0032] As seen in FIG. 1, a blow-by mixture follows a path 170 from
the crankcase 103 to the coalescer 110. One or more components or
aspects of the diesel engine 102 and/or the coalescer system 111
may be interposed between the coalescer 110 and the crankcase 103
along the path 170. For example, the blow-by mixture may follow the
path 170 from the crankcase 103 (e.g., from an outlet port or
fitting of the crankcase 103) to the IFE 104 (it may be noted that
in some examples, the crankcase may form a part of the IFE 104),
from the IFE 104 to the blow-by input module 120, and from the
blow-by input module 120 to the coalescer 110 (e.g., through the
blow-by input module 120 and into the coalescer 110 via an inlet
port or fitting of the coalescer 110). The various blocks or
components may include one or more ports for accepting the flow
and/or expelling the flow therefrom, as well as one or conduits for
passage of the flow. For example, the coalescer 110 may include a
blow-by inlet port, the crankcase 103 may include a blow-by outlet
port, and the blow-by input module 120 may include one or more
pipes, tubes, hoses, fittings, or the like. The blow-by mixture is
accepted by the coalescer 110, and the coalescer 110 separates oil
from a gas (e.g., a gaseous fuel/air mixture) to provide an oil
drain supply and a gas vent supply that exit from the coalescer
110.
[0033] The coalescer 110 also receives a boost air supply that
follows a path 180 from the intake conduit 108 to the boost air
intake module 130, and from the boost air intake module 130 to the
coalescer 110. The boost air supply provides an operational air
supply, for example to operate a vacuum or other pressure
differential utilized by the coalescer 110 to separate oil from the
blow-by mixture. The gas separated from the oil as well as any of
the used boost air supply may be removed from the coalescer 110 via
a path 182. The path 182 flows from the coalescer 110 to the gas
output module 150 (e.g., from an outlet port or fitting of the
coalescer 110), and from the gas output module 150 to the exhaust
conduit 109 of the diesel engine 102 (e.g., through the gas output
module 150 to the exhaust conduit 109 via a stack outlet 152). The
gas output module 150, for example, may be secured to the turbo
unit 107 via a hose support 154. It may be noted that "P1" depicted
at an entry to the exhaust conduit 109 may be lower than "P2"
depicted at an exit of the crankcase 103 for the blow-by mixture to
allow one or more of the indicated flows to occur.
[0034] Once the oil has been separated from the blow-by mixture,
the oil may be provided from the coalescer 110 to the oil reservoir
105 along a path 190. The path 190 in the illustrated embodiment
flows from the coalescer 110 to the oil output module 150. The path
190 may flow from the coalescer 110 to the oil output module 140
(e.g., from an outlet port or fitting of the coalescer 110 into the
oil output module 140), and from the oil output module 140 to the
oil reservoir 105 (e.g., through the oil output module 140 and into
the oil reservoir 105 via an inlet port or fitting of the oil
reservoir 105). Oil may be distributed from the oil reservoir 105
to one or more locations of the diesel engine 102 for
lubrication.
[0035] The coalescer 110 is configured to separate oil from a
gaseous flow of the blow-by mixture obtained from or provided by
the crankcase 103. The coalescer 110 may also be configured to act
as a filter (e.g., for particulate) as well. In the illustrated
embodiment, the coalescer 110 is configured as a multi-stage
coalescer. For example, the coalescer 110 may include a
pre-separator portion (e.g., a cyclonic pre-separator) that
provides an initial separation of oil from the blow-by mixture.
Following the pre-separator, the coalescer 110 may have a first
stage separator and a second stage separator. The blow-by mixture
may enter the first stage separator were oil particles are absorbed
by a diaphragm (e.g., a flexible diaphragm made of one or more of
paper, rubber, or the like). After the first stage, the blow-by
mixture may enter the second stage separator were further
separation of the oil from the gases takes place under higher
pressure. A vacuum for the second stage (to create a higher
pressure differential) may be created using boost air supplied from
the intake conduit 108 to the coalescer 110 via the boost air
intake module 130. The created vacuum, for example, may assist in
squeezing the diaphragm and removing oil from the diaphragm.
[0036] It may be noted that in various embodiments, the block
corresponding to the coalescer 110 may include more than one
coalescer, for example two or more coalescers configured in
parallel and receiving and/or providing flows via manifolds that
form portions of the various modules operably coupling the
coalescer with various portions, systems, components, or aspects of
the diesel engine 102. FIG. 3 provides a perspective view of a
coalescer system 300 that includes three coalescers. (The
embodiment depicted in FIG. 2 also includes three coalescers.) The
coalescer system 300 includes a first coalescer 310, a second
coalescer 312, and a third coalescer 314. The coalescers 310, 312,
314 are coupled in parallel to a crankcase (e.g., crankcase 103) to
receive a blow-by mixture via an input manifold 320 that forms part
of a blow-by input module (e.g., blow-by input module 150).
Similarly, the coalescers 310, 312, 314 are coupled in parallel to
the exhaust system (e.g., exhaust conduit 109) of a diesel engine
via an output manifold 330 that forms part of a gas output module
(e.g., gas output module 150). Further, the coalescers 310, 312,
314 are coupled in parallel to an oil reservoir (e.g., oil
reservoir 105) of a diesel engine via an oil output manifold 340
that forms part of an oil output module (e.g., oil output module
140). Further, the coalescers 310, 312, 314 are coupled in parallel
to a boost air supply (e.g., from an intake system or component
such as the intake conduit 108) of a diesel engine via a boost air
manifold 350 that forms part of a boost air module (e.g., boost air
module 130). A bracket 360 secures the coalescers 310, 312, 314 in
place. By providing a plurality of coalescers (e.g., three or more
coalescers mounted to available space proximate an intercooler
disposed proximate a front end of the diesel engine) various
embodiments provide for substantial improvement in the amount of
oil that may be removed from blow-by gases in comparison to
conventional mountings and arrangements that only allow for a
single coalescer, and/or conventional mountings and arrangements
that provide less advantageous pathways or conduits for the passage
of gases and/or liquids between the coalescers and one or more
aspects of a diesel engine.
[0037] Certain modules described herein are configured to provide
conduits or passageways for the passage of flow between the
coalescer 110 and the diesel engine 102. The modules may be
configured for passage of fluids (e.g., gases, liquids, or a
mixture thereof). The modules may not be understood as a part of a
coalescer itself, but instead understood as providing a route,
path, and/or passageway for distributing one or more fluids to the
coalescer and/or from the coalescer. FIG. 4 provides a view of an
example conduit module 400 formed in accordance with an example of
the present inventive subject matter. One or more of the applies to
blow-by input module 120, a boost air intake module 130, an oil
output module 140, an outlet gas module 150 may be generally
configured similarly to or include or incorporate one or more
aspects of the conduit module 400.
[0038] As seen in FIG. 4, the conduit module 400 includes an inlet
port 410, a first hose 420, a pipe 430, a second hose 440, an
outlet port 450, and fittings 460. It may be noted that the
particular arrangement depicted in FIG. 4 is provided by way of
example only, and that, for example, additional segments of pipe
and/or hose may be provided in various examples. As another
example, one or more of the aspects shown in FIG. 4 may include or
be configured as a manifold having a plurality of inlets or
outlets, for example, for a corresponding plurality of
coalescers.
[0039] The inlet port 410 is configured to be operably connected to
a component or aspect of a coalescer or diesel engine, and to
receive a flow from the component or aspect to which the inlet port
410 is connected. The inlet port 410, for example, may include a
threaded fitting. The inlet port 410 is configured to be operably
connected to a component or aspect of a coalescer or diesel engine,
and to receive a flow from the component or aspect to which the
inlet port 410 is connected. The inlet port 410, for example, may
include a threaded fitting. The outlet port 450 is configured to be
operably connected to a component or aspect of the coalescer or
diesel engine, and to provide a flow to the component or aspect to
which the outlet port 450 is connected. The outlet port 450, for
example, may include a threaded fitting.
[0040] The first hose 420, the pipe 430, and the second hose 440
form a pathway between the inlet port 410 and the outlet port 450
through which a flow may pass from the coalescer to a portion or
aspect of the diesel engine, and/or vice versa. The first hose 420
and the second hose 440 may be flexible hoses configured to allow
for convenient positioning of the inlet port 410 and outlet port
450 and joining of the ports to ports or fittings of the coalescer
and/or aspects of the diesel engine. The pipe 430 is interposed
between the first hose 420 and the second hose 440, and may be
generally rigid or inflexible. The pipe 430 may provide for
convenient mounting to engine components (e.g., via clamps, joints,
or the like) while also providing rigidity and durability. The pipe
430 may include one or more elbows configured to provide a desired
shape (e.g., to traverse around a given portion of the engine). The
combination of the hoses and the pipe provide for a rigid, durable
fluid path while still allowing for flexibility for installation
and mounting convenience. The fittings 460 provide a fluid-tight
joining between the hoses and the pipe 430.
[0041] As one example, the conduit module 400 may be configured as
a boost air intake module, and may have an engine fitting (e.g.,
inlet port 410) that mates with an outlet of the intake conduit
108, as well as a coalescer fitting (e.g., outlet port 450) that
mates with an inlet of the coalescer 110, with a boost air supply
being provided from the intake of the engine to the coalescer via
the conduit module 400.
[0042] Returning to FIG. 1, as indicated above, the depicted
blow-by input module 120 is configured to receive a blow-by mixture
from the crankcase 103 and provide the blow-by mixture to the
coalescer 110. The blow-by input module 120 may be understood as a
conduit between the coalescer 110 and the crankcase 103 through
which a blow-by mixture flows from the crankcase to the coalescer
110. The blow-by input module 120 may include a port or manifold
for providing the blow-by mixture to one or more coalescers.
[0043] FIG. 5 provides a perspective view of a blow-by input module
500 formed in accordance with an example of the present inventive
subject matter (see also FIG. 2 for an additional view of the
depicted assembly). The blow by input module 500 is configured to
provide a blow-by mixture from the crankcase 502 and/or IFE
assembly 504 to one or more coalescers 506 (see, e.g., FIG. 3 and
related discussion for an example of a blow-by inlet manifold).
[0044] The depicted blow-by input module 500 includes a pipe 510, a
manifold 520, a clamp 530, and a threaded fitting 540. The threaded
fitting 540 is configured to provide a fluid-tight joining with the
IFE assembly 504 for the passage of the blow-by mixture from the
diesel engine into the blow-by input module 500. The pipe 510
provides a pathway between the IFE assembly 504 and the
coalescer(s) 506. The pipe 510 may include one or more bends,
elbows, curved portions, or the like to conform to a desired and/or
available pathway (e.g., to minimize or reduce the distance
traveled by the blow-back mixture while still providing for
convenient assembly and/or maintenance). The manifold 520 may be
flexible (e.g., a flexible length of tubing or hose) and include a
plurality of outlets for a corresponding plurality of coalescers.
The manifold 520 (e.g., the manifold outlets) may be secured to the
coalescers via clamps (e.g., a hose clamp proximate to each inlet
of the coalescers). The clamp 530 is configured to secure the pip
510 to a portion of a diesel engine, such as an EGR cooler 505.
[0045] Returning to FIG. 1, the illustrated boost air intake module
130 is configured to receive an air supply from the intake conduit
108 of the diesel engine 102, and to provide the air supply as an
operational air supply to the coalescer 110. An operational air
supply as used herein may be understood to include a supply of air
used by the coalescer 110 to separate portions of a different
supply or stream (e.g., a blow-by mixture from a separate stream or
flow-path than the operational air supply). For example, the air
supply provided via the air intake module 130 may be configured to
provide a vacuum used to separate oil from other components of the
blow-by mixture. The air intake module 130 may be understood as a
conduit between the air intake conduit 108 and the coalescer 110
through which an operational air supply flows from the intake
conduit 108 to the coalescer 110. The boost air intake module 130
may include a port or manifold for providing the blow-by mixture to
one or more coalescers.
[0046] FIG. 6 provides a perspective view of a boost air intake
module 600 formed in accordance with an example of the present
inventive subject matter (see also FIG. 2 for an additional view of
the depicted assembly). The depicted boost air intake module 600 is
configured to receive an air supply from the intake conduit 602 of
a diesel engine (e.g., intake pipe) and to provide a boost air
supply to one or more coalescers 604 (e.g., an air supply used to
provide a vacuum for improved separation of oil and gases in the
blow-by mixture provided from a crankcase) to the one or more
coalescers 604.
[0047] The depicted boost air intake module 600 includes an inlet
port 610, a boost air hose 620, and a boost air manifold 630. The
inlet port 610 is configured to receive an air supply from the
intake conduit 602. The inlet port 610, for example, may include a
threaded fitting accepted by a thread of the intake conduit 602 to
provide an air-tight seal for passage of air from the intake
conduit 602 into the boost air hose 620. The boost air hose 620 may
be flexible to provide for convenient installation and routing. The
boost air manifold 630 may be flexible (e.g., a flexible length of
tubing or hose with one or more fittings to outlet ports and/or
outlet segments of hose or tubing) and include a plurality of
outlets for a corresponding plurality of coalescers.
[0048] With returned reference to FIG. 1, the depicted oil output
module 140 is configured to receive an oil drain supply provided by
the coalescer 110 (e.g., a supply of oil separated from the blow-by
mixture by the coalescer 110), and to provide the oil drain supply
to the oil reservoir 105. The oil output module 140 may be
understood as a conduit between the coalescer 110 and the oil
reservoir 108 through which oil separated from a blow-by mixture
flows from the coalescer 110 to the oil reservoir 108. The oil
output module 140 may include a port or manifold for accepting oil
supplied from one or more coalescers (e.g., oil separated from a
blow-by mixture by the one or more coalescers).
[0049] FIG. 7 provides a perspective view of an oil output module
700 formed in accordance with an example of the present inventive
subject matter (see also FIG. 2 for an additional view of the
depicted assembly). The oil output module 700 is configured to
provide oil separated by one or more coalescers from a blow-by
mixture from the one or more coalescers to an oil reservoir 702
(e.g., oil pan). The oil returned to the oil reservoir 702 may then
be used from lubrication purposes for one or more systems, aspects,
or components of the diesel engine. For example, oil from the oil
reservoir 702 may be used to provide lubrication for the crank of
the diesel engine.
[0050] The depicted oil output module 700 includes a manifold (not
shown in FIG. 7; for an example of a manifold for an oil output
module, see oil output manifold 350 of FIG. 3), an outlet port 710,
and an oil hose 720. Oil from one or more coalescers may be
provided to the oil reservoir 702 via the oil hose 720, with the
oil hose 720 fluidly coupled with one or more coalescers via a port
or manifold. It may be noted that the oil hose 720 may be devoid of
an oil trap. The outlet port 710, which may have one or more elbows
and/or turns and terminate in a threaded fitting accepted by the
oil reservoir 702, is configured to provide a fluid tight seal
between the oil hose 720 and the oil reservoir 702. By returning
the oil separated from the blow-by mixture to the oil reservoir
702, various embodiments reduce waste of oil and/or reduce
emissions related to the venting of oil to the atmosphere.
[0051] Returning to FIG. 1, the outlet gas module 150 is configured
to receive a gas vent supply from the coalescer 110 and provide the
gas vent supply to the exhaust conduit 108. The outlet gas module
150 may be understood as a conduit between the coalescer 110 and
the exhaust conduit 108 through which gases to be vented to the
atmosphere (e.g., gases from which oil has been separated and/or
gases from a boost air supply) flow from the coalescer 110 to the
exhaust conduit 108 of the diesel engine 102. The outlet gas module
150 may include a port or manifold for accepting outlet gases from
one or more coalescers (e.g., gases from which oil has been
separated by the one or more coalescers)
[0052] FIGS. 8 and 9 provide perspective views of an outlet gas
module 800 formed in accordance with an example of the present
inventive subject matter (see also FIG. 2 for an additional view of
the depicted assembly). The outlet gas module is configured to
provide outlet gases from one or more coalescers 802 to an exhaust
conduit 804. For example, the exhaust conduit 804 may be a muffler
of an exhaust system configured for the expulsion of products of
combustion from the diesel engine.
[0053] The depicted outlet gas module includes an outlet gas
manifold 810, outlet gas piping 820, clamps 830, and a stack outlet
840. The outlet gas manifold, which may be made of a generally
flexible material, accepts outlet gases from the one or more
coalescers 802. The outlet gases 802 pass through the outlet gas
piping 820 and into the exhaust conduit 804 via the stack outlet
840. The stack outlet 840, for example, may be configured as an
exit port of the outlet gas module 800 and have a threaded fitting
accepted by a port of the exhaust conduit 804 (e.g., a port or
inlet disposed on a muffler). The clamps 830, which may be
configured as "p"-shaped claims, may be used to secure the outlet
gas piping 820 in place.
[0054] Returning to FIG. 1, the bracket 160 is configured to secure
the coalescer 110 to the diesel engine 102. In the illustrated
embodiment, the coalescer 110 is secured to the diesel engine 102
proximate the front end 198 of the diesel engine 102, for example
to an intercooler 106, via the bracket 160. For example, the
bracket 160 may be secured to an EGR intercooler disposed on the
front end 198 of the diesel engine 102 generally directly below an
air intake of the diesel engine 102. The EGR intercooler may
provide, for example, a sufficient area to mount one or more
coalescers without requiring removing or re-routing other engine
components, and/or provide for a relatively short travel distance
for one or more of a hose from an intake conduit to one or more
coalescers, a hose from one or more coalescers to an oil reservoir,
a conduit from one or more coalescers to an exhaust stack, or a
conduit from a crankcase to one or more coalescers.
[0055] FIGS. 10, 11, and 12 provide perspective views of a bracket
assembly 1000 formed in accordance with an example of the present
inventive subject matter (see also FIG. 2 for an additional view of
the depicted assembly). The bracket assembly 1000 is configured to
mount one or more coalescers 1002 (e.g., three coalescers in the
depicted embodiments) to an intercooler 1004 disposed at the front
end of a diesel engine. For example, the intercooler 1004 may be an
EGR cooler. The depicted bracket assembly 1000 includes a bracket
base 1010 and bracket arms 1020. The bracket base 1010 is
configured to mount to the intercooler 1004. The bracket arms 1020
define cavities 1024 that accept at least a portion of one of the
coalescers 1002. The bracket arms 1020 are securable to the bracket
base 101 to secure the coalescers 1002 to the intercooler 1004.
[0056] For example, as best seen in FIG. 10, the bracket base 1010
is configured to be mounted to the intercooler 1004 via bolts 1012.
The intercooler 1004 may be configured with a thicker surface, a
raised surface, pads, or the like to allow sufficient depth of
threaded holes for securing the bracket base 1010 to the
intercooler 1004. As seen in FIG. 10, the depicted bracket base
1010 includes mounting areas 1014. The mounting areas 1014 are
configured as raised surfaces for mounting of the bracket arms 1020
to the bracket base 1010.
[0057] With the bracket base 1010 secured to the intercooler 1004,
the bracket arms 1020 may be secured to the bracket base 1010. As
best seen in FIG. 11, the bracket arms 1020 may be secured to the
bracket base 1010 via bolts 1022. The bolts 1022 may thread into an
edge of the raised surfaces of the mounting areas 1014, or, as
another example, may be used to secure the bracket arms 1020 to the
mounting areas 1014 via a clamping action. The bolts 1022 may
further include additional threading portions for securing the
coalescers 1002 to the bracket arms 1020. The bracket arms 1020
define cavities 1024 that accept the coalescers 1002. In FIG. 11,
two bracket arms 1020 are shown securing one coalescer 1002 in a
central cavity defined by an internal portion (e.g., oriented
toward the center of the bracket 1000) of each bracket arm 1020.
Further, each bracket arm 1020 defines a cavity 1024 unique to that
particular arm oriented as an external cavity (e.g., toward an edge
of the bracket 1000) configured to accept an additional coalescer,
so that the depicted bracket 1000 may accept and secure three
coalescers 1002 to the intercooler 1004. FIG. 12 provides a view of
three coalescers 1002 secured to the intercooler 1004.
[0058] Mounting a coalescer proximate the front end of an engine,
for example as depicted in FIGS. 10-12, may provide for a secure
mounting location large enough to accept plural coalescers, provide
for convenient installation and subsequent access to aspects of a
coalescer system, and/or provide for relatively short conduit runs
between a coalescer and pertinent aspects of the diesel engine.
Further, the coalescer mounting depicted in FIGS. 10-12 may fit
entirely or nearly entirely within a defined volumetric envelope of
the engine without the coalescers, allowing for convenient fit
within an engine cab.
[0059] It may be noted, however, that alternate mounting positions
may be employed in various alternate embodiments. For example, FIG.
13 provides a perspective view of an alternate mounting of a
coalescer system 1300 in accordance with an example of the present
inventive subject matter. The various flows into and out of a
coalescer 1310 of the coalescer system 1300 may be generally
similar as for the coalescer 110 discussed in connection with FIGS.
1 and 2. However, as seen in FIG. 13, the coalescer 1310 of the
coalescer system 1300 is mounted to a cam cover 1303 of an engine
block 1302 via a bracket 1320. As seen in FIG. 13, the coalescer
1310 may be understood as being mounted parallel to the cam cover
1303. As each cam cover may have a coalescer mounted thereto, the
arrangement of FIG. 13 provides for the use of multiple
coalescers.
[0060] In contrast to the examples discussed in connection with
FIGS. 1-12, however, the blow-by mixture may be provided to the
coalescer 1310 from the rear end of a diesel engine (e.g., the end
opposite an air intake opening). Further, a boost air supply may be
provided from a port disposed at a rear end of an intake manifold
receiving air from the intake opening at the front end of the
engine. Depending on the specific layout of the engine, an
arrangement as shown in FIG. 13, when compared to the arrangement
of FIGS. 1-12, may require additional lengths of conduits from the
coalescer to pertinent aspects of the diesel engine, result in
challenges providing clearance from the engine cab 1304, have
reduced convenience of access and serviceability, or the like.
[0061] FIG. 14 provides a perspective view of an additional
alternate mounting of a coalescer system 1400 in accordance with an
example of the present inventive subject matter. The various flows
into and out of a coalescer 1410 of the coalescer system 1400 may
be generally similar as for the coalescer 110 discussed in
connection with FIGS. 1 and 2. However, as seen in FIG. 14, the
three coalescers 1410 of the coalescer system 1400 are mounted, via
a bracket 1420, to oil cooler 1402 of a diesel engine. Similar to
examples discussed in connection with FIGS. 1-12, the coalescers
1410 may be mounted at or near the front end of a diesel
engine.
[0062] However, mounting the coalescers 1410 on top of the oil
cooler moves the coalescers outside of an engine environment, in
contrast to the mounting depicted in FIGS. 10-12. Thus, while the
coalescers 1002 or coalescer 110 may be installed on the engine
prior to mounting or installing the engine on a vehicle, the
coalescers 1410 may be installed after the engine and oil cooler
are installed, which can lead to more difficult installation.
Further, the oil cooler 1402 may be more susceptible to movement
than, for example, an EGR intercooler. Further, the oil cooler may
be required to be dismantled before servicing the coalescers 1410,
in contrast to the coalescer 110 or coalescers 1002 which may be
serviced without dismantling other engine components. Compared to
the examples of FIGS. 10-12, the mounting depicted in FIG. 14 may
result in increased complexity and lengthening of piping and/or
hosing runs form the coalescer to the pertinent aspects of the
diesel engine.
[0063] FIG. 15 illustrates a flowchart of a method 1500 for
providing and/or using a coalescing system in accordance with an
example of the present inventive subject matter. The method 1500
may be performed, for example, using certain components, equipment,
structures, or other aspects of embodiments discussed herein. In
certain embodiments, certain steps may be added or omitted, certain
steps may be performed simultaneously or concurrently with other
steps, certain steps may be performed in different order, and
certain steps may be performed more than once, for example, in an
iterative fashion.
[0064] At 1502, a bracket and one or more coalescers are mounted to
a diesel engine. The bracket may be configured to secure the one or
more coalescers in place and may be mounted to a portion of the
engine. For example, the bracket and one or more coalescers may be
mounted to a readily accessible exterior surface of an intercooler
(e.g., an EGR intercooler) disposed proximate a front end of the
diesel engine. (See, e.g., FIGS. 10-12.) The coalescer in various
examples is configured to receive a blow-by mixture from the diesel
engine, and to separate oil in the blow-by mixture from one or more
gases (e.g., a fuel/air mixture) of the blow-by mixture. The
coalescer may provide a gas vent supply of the gases and an oil
drain supply of the separated oil. The coalescer may also be
configured to receive a boost air supply, for example, to provide a
vacuum for improved separation of oil from the gases in the blow-by
mixture.
[0065] In some examples, the mounting of the bracket and one or
more coalescers may be performed using substeps 1504-1508. At 1504,
a bracket base is mounted to a surface of an EGR cooler, for
example using bolts. At 1506, bracket arms defining cavities are
secured to the bracket base. At 1508, one or more coalescers are
secured to the EGR intercooler via the bracket arms and base. For
example, each coalescer may be bolted, clamped, or the like to one
or more bracket arms. It may be noted that the substeps 1506 and
1508 may be performed simultaneously, concurrently, or iteratively.
For example, to mount three coalescers, a first coalescer unit may
be mounted between two bracket arms which are then secured to the
bracket base. The two remaining intercoolers may subsequently each
be secured within an external cavity of the two bracket arms,
respectively. (See, e.g., FIGS. 11-12.)
[0066] At 1510, a blow-by input module is operably connected
between at least one coalescer and a crankcase of the diesel
engine. The blow-by input module receives the blow-by mixture from
a crankcase of the diesel engine and provides the blow-by mixture
to the at least one coalescer. The blow-by input module may include
one or more of a pipe, hose, port, manifold, fitting, or the
like.
[0067] At 1512, a boost air module is operably connected between
the at least one coalescer and an intake conduit of the diesel
engine. The boost air module receives an air supply from an intake
conduit of the diesel engine and provides the air supply as the
operational air supply (e.g., an air supply used to provide a
vacuum or pressure differential for improved separation) to the at
least one coalescer. The boost air module, for example, may include
a hose leading from an intake conduit of the diesel engine to
fittings or ports of one or more coalescers.
[0068] At 1514, an outlet gas module is operably connected between
the at least one coalescer and an exhaust conduit (e.g., muffler)
of a diesel engine. The outlet gas module is configured to receive
the gas vent supply from the at least one coalescer and to provide
the gas vent supply to the exhaust conduit of the diesel engine.
The outlet gas module may include one or more of a pipe, hose,
port, manifold, fitting, or the like.
[0069] At 1516, an oil output module is operably connected between
the at least one coalescer and an oil reservoir of the diesel
engine. The oil output module receives the oil drain supply from
the at least one coalescer and provides the oil drain supply to the
oil reservoir of the diesel engine. The oil output module, for
example, may include a hose leading from the at least one coalescer
to a fitting or port of the oil reservoir (e.g., oil pan).
[0070] At 1518, the at least one coalescer is operated, for
example, pursuant to substeps 1520-1528. With the diesel engine
running, blow-by mixture from the crankcase is routed to the at
least one coalescer at 1520. At 1522, the coalescer receives a
boost air supply from an intake conduit of the diesel engine via
the boost air module to provide improved separation. Using the
boost air supply, at 1524, the at least one coalescer separates the
blow-by mixture to a gaseous stream or gas vent supply and to an
oil drain supply include oil separated from the gases received from
the crankcase. At 1526, the gas vent supply is provided to the
exhaust conduit and expelled to the atmosphere, while, at 1528, the
oil drain supply is returned to the oil reservoir for further use
by the diesel engine.
[0071] In an example of the present inventive subject matter, a
coalescing system includes at least one coalescer, a blow-by input
module, and a boost air module. The at least one coalescer is
configured to receive a blow-by mixture from an internal combustion
engine, to remove oil from the blow-by mixture to provide an oil
drain supply from the at least one coalescer, and to remove gas
from the blow-by mixture to provide a gas vent supply from the at
least one coalescer. The coalescer is configured to receive an
operational air supply. The blow-by input module is operably
coupled to the at least one coalescer and configured to receive the
blow-by mixture from a crankcase of the internal combustion engine
and provide the blow-by mixture to the at least one coalescer. The
boost air module is operably coupled to the at least one coalescer
and configured to receive an air supply from an intake conduit of
the internal combustion engine and to provide the air supply as the
operational air supply to the at least one coalescer.
[0072] In another aspect, the coalescing system further includes an
outlet gas module operably coupled to the at least one coalescer
and configured to receive the gas vent supply from the coalescer
and to provide the gas vent supply to an exhaust conduit of the
internal combustion engine.
[0073] In another aspect, the coalescing system further includes an
oil output module operably coupled to the at least one coalescer
and configured to receive the oil drain supply from the at least
one coalescer and to provide the oil drain supply to an oil
reservoir of the internal combustion engine.
[0074] In another aspect, the coalescing system further includes a
bracket configured to mount the at least one coalescer to a front
end of the internal combustion engine, the front end corresponding
to an intake end of the internal combustion engine. For example,
the bracket may be configured to mount the at least one coalescer
to an intercooler disposed on the front end of the internal
combustion engine. Further, the bracket may include a bracket base
and at least one bracket arm, with the bracket base configured to
mount to the intercooler, and the at least one bracket arm defining
at least one cavity configured to accept at least a portion of the
at least one coalescer. The at least one bracket arm may be
securable to the bracket base to secure the at least one coalescer
to the intercooler.
[0075] In another aspect, the at least one coalescer includes a
plurality of coalescers, and the at least one bracket arm comprises
a plurality of bracket arms configured to secure the plurality of
coalescers to the intercooler.
[0076] In another aspect, the blow-by input module comprises at
least one rigid pipe and at least one flexible hose.
[0077] In an example of the present inventive subject matter, a
system includes an internal combustion engine, at least one
coalescer, a blow-by input module, and a boost air module. The
internal combustion engine includes an intake conduit configured to
provide an inlet stream of air for combustion by the internal
combustion engine, a crankcase, an exhaust conduit configured to
provide an outlet for combustion products, and an oil reservoir.
The at least one coalescer is configured to receive a blow-by
mixture from the crankcase of the internal combustion engine, to
remove oil from the blow-by mixture to provide an oil drain supply
from the at least one coalescer, and to remove gas from the blow-by
mixture to provide a gas vent supply from the at least one
coalescer. The coalescer is also configured to receive an
operational air supply. The blow-by input module is operably
coupled to the at least one coalescer and configured to receive the
blow-by mixture from the crankcase of the internal combustion
engine and provide the blow-by mixture to the at least one
coalescer. The boost air module is operably coupled to the at least
one coalescer and configured to receive an air supply from the
intake conduit of the internal combustion engine and to provide the
air supply as the operational air supply to the at least one
coalescer.
[0078] In another aspect, the system also includes an outlet gas
module operably coupled to the at least one coalescer and
configured to receive the gas vent supply from the at least one
coalescer, and to provide the gas vent supply to the exhaust
conduit of the internal combustion engine.
[0079] In another aspect, the system also includes an oil output
module operably coupled to the at least one coalescer and
configured to receive the oil drain supply from the at least one
coalescer, and to provide the oil drain supply to the oil reservoir
of the internal combustion engine.
[0080] In another aspect, the system includes a bracket configured
to mount the at least one coalescer to a front end of the internal
combustion engine, with the front end corresponding to an intake
end of the internal combustion engine. For example, the bracket may
be configured to mount the at least one coalescer to an intercooler
disposed on the front end of the internal combustion engine.
[0081] In an example of the present inventive subject matter, a
method includes positioning at least one coalescer proximate to an
internal combustion engine. The at least one coalescer is
configured to receive a blow-by mixture from an internal combustion
engine, to remove oil from the blow-by mixture to provide an oil
drain supply from the at least one coalescer, and to remove gas
from the blow-by mixture to provide a gas vent supply from the at
least one coalescer. The coalescer is configured to receive an
operational air supply. The method also includes operably
connecting a blow-by input module to the at least one coalescer and
to a crankcase of the internal combustion engine, wherein the
blow-by input module receives the blow-by mixture from a crankcase
of the internal combustion engine and provides the blow-by mixture
to the at least one coalescer. Further, the method includes
operably connecting a boost air module to the at least one
coalescer and an intake conduit of the internal combustion engine,
wherein the boost air module receives an air supply from an intake
conduit of the internal combustion engine and provides the air
supply as the operational air supply to the at least one
coalescer.
[0082] In another aspect, the method includes operably coupling an
outlet gas module to the at least one coalescer and an exhaust
conduit of the internal combustion engine, wherein the outlet gas
module receives the gas vent supply from the coalescer and provides
the gas vent supply to the exhaust conduit of the internal
combustion engine.
[0083] In another aspect, the method includes operably coupling an
oil output module to the at least one coalescer and to an oil
reservoir of the internal combustion engine, wherein the oil output
module receives the oil drain supply from the at least one
coalescer and provides the oil drain supply to the oil reservoir of
the internal combustion engine.
[0084] In another aspect, the method includes securing the at least
one coalescer to a front end of the internal combustion engine, the
front end corresponding to an intake end of the internal combustion
engine. For example, securing the at least one coalescer to the
front end of the internal combustion engine may include securing
the at least one coalescer to an intercooler disposed proximate the
front end of the internal combustion engine. For instance, securing
the at least one coalescer to the intercooler may include securing
a bracket base to the intercooler, and securing one or more bracket
arms to the bracket base, with the one or more bracket arms
comprising at least one cavity configured to accept at least one of
the at least one coalescers.
[0085] In another aspect, the at least one coalescer comprises
three coalescers mounted to an intercooler disposed proximate a
front end of the internal combustion engine
[0086] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
without departing from its scope. While the dimensions and types of
materials described herein are intended to define the parameters,
they are by no means limiting and are exemplary embodiments. Many
other embodiments will be apparent to one of ordinary skill in the
art upon reviewing the above description. The scope should,
therefore, be determined with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled. In the appended claims, the terms "including,"
"includes," and "in which" are used as the plain-English
equivalents of the respective terms "comprising," "comprises," and
"wherein." Moreover, in the following claims, the terms "first,"
"second," and "third," etc. are used merely as labels, and are not
intended to impose numerical requirements on their objects.
Further, the limitations of the following claims are not written in
means-plus-function format and are not intended to be interpreted
based on 35 U.S.C. .sctn.112(f), unless and until such claim
limitations expressly use the phrase "means for" followed by a
statement of function void of further structure.
[0087] This written description uses examples to disclose several
embodiments, and also to enable any person skilled in the art to
practice the embodiments, including making and using any devices or
systems and performing any incorporated methods. The patentable
scope is defined by the claims, and may include other examples that
occur to one of ordinary skill in the art. Such other examples are
intended to be within the scope of the claims if they have
structural elements that do not differ from the literal language of
the claims, or if they include equivalent structural elements with
insubstantial differences from the literal languages of the
claims.
[0088] As used herein, an element or step recited in the singular
and proceeded with the word "a" or "an" should be understood as not
excluding plural of said elements or steps, unless such exclusion
is explicitly stated. Furthermore, references to "one embodiment"
are not intended to be interpreted as excluding the existence of
additional embodiments that also incorporate the recited features.
Moreover, unless explicitly stated to the contrary, embodiments
"comprising," "including," or "having" an element or a plurality of
elements having a particular property may include additional such
elements not having that property.
[0089] Since certain changes may be made in the above-described
systems and methods, without departing from the spirit and scope of
the embodiments described herein, it is intended that all of the
subject matter of the above description or shown in the
accompanying drawings shall be interpreted merely as examples
illustrating the inventive subject matter herein and shall not be
construed as limiting.
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